Manufacture of mosaic fabrics



Nov. 22, 1932. E. c. DEARDEN 1,888,492

` MANUFACTURE oF MosAIc FABRICS Filed Jan. 17, 195o Ivy-2. f; /l V u j l/ u Il Y l /l YL `6 4 vim im softened by heat.

Patented Nov. 22, 1932 nutren sra. :Es @Par-snr laries y EDWARD C. DEA-BEEN, `Oli' MERIQN', ,BENNSYLYN'Il-L, `.ASSICUT R., BY MESNE ASSIGN- MENTS, TO SLOANErBLABQ'N CQREQM'EION, NEEN YORK, N. Y., A CORPORATION F DELAWARE MANUJACTUB@ CIF MOSAIC FABRICS Application led VJanuary 17, 1930. Serial No. 421,368.

My invention 'is designed to'provide alaminatedrmosaic fabric suitable for'lloor coverings and the'flike, and havingfthe-'design or pattern accentuated by inequalities in the saic, and particularly vby the depression of tesseree or strips forming joint-like-spaces between the more prominent 'tesserae or resulting from embossing an assembled linoleum product, or from subjecting the tesserae to ,unequal pressures With resulting variations in density, or Afrom attelnpting'to unite the edgesrof tesserae of dissimilar type andicondition, such, `for insta-nce, as tessera;- of .cured and uncuredlinoleum.

By my improvements there is provided a flexible laminated: mosaic Vfabric having a surface in relief, and composed of tesseraeof substantially uniform density .homogeneously united along theedges of abutting tesserae, all of which are composed of moulded Vgranular linoleumcomposition of analogous texture and intermingled before curi-ng, but havingy nishedf surfaces of different heights due to ditl'erences Vin the depth ofl material deposited for different tesserze, the ydeposits i of different depths being separatelyl compactedbefore curing.

ln accordance With my improvements, .a flexible backing, such as burla-p, felt, or the like, has depositedthereon uncured granular linoleum compositionin Athe formlo'f intersecting ribs or ridges or of spaced tesserae preferably providing a skeleton outline of a pattern. Such composition is compactedfby means of a suitable press or rollers While The lattice lor grid formed -by the compacted ribs orbands of deposited llnoleumhas the-'spaces or intersticesb-etween the ribs or spaced tesseraevilled With uncured gran- 4'5' ulated plastic liuoleum composition to a depth greaterthan the depth of the original deposits, so that when such secondary deposits or insets are compacted by meansV of 4a l press, Whilesoftenedby heat, theyare intimately united with the uncured previously surfacelevel of the tesserae forming themocompacted-primary deposits, but projected above thesame. The lower surfaced tesserae definitely outline the contour of the -pattern and produce lightand shadow lines ofpleasing elfect, giving particularly a close simulation of tile, slate-stone, iiagstOne, brick or other paving plaques laid in mortar.

In the-preferred practice of my invention, the backingis moved stepby step beneath one or more stencils or templates having cut therein slots or apertures for the passage of granular material, which, when deposited, outline a desired slteletonpattern. Thenumber of templates or stencils used for the deposit ofthe material forming the lower portions of the surface Will depend upon the number of colors desired in the depressed portion ofthe product, and Where almortar join-teflect is desired a single stencil Will ordinarilyy su'llice forthe depositof thecomposition there-for. y

The plastic material '.to be attached "topthe backing, such as unseasoned granular linoleu'm composition, may be swept overthesurface ofithelirst stencil, and the .portion thereof ypassing through the stencil openings forms outline ribs or spaced tesserae on Vthe backing to a depth equal'to 'the space between the top of the backing and the stencil. 'If more thanone stencil is used for the deposit of ribs or spaced tesserae, the burlap is'moved stepv by step beneath the stencils in sequence and receives deposits lfrom each stencil. The material so deposited is softened by heat and attached to the backing by pressure, 4resultingy in the production of a. backing having thereon a projecting reticulated pattern of uncured composition with openings or recesses therein.

After thecompacting of the initial deposit, the backing is moved step by step beneathone or more additional templates 'having apertures for the passage of material'to fill'the openings or recesses in the pattern to a greater depth than the original deposit. The number of templatesor stencils used for the deposit of material forming insetsv will dependupon the number of colors desiredl in the inserts, a separate stencil beingusually usedfor each color desired. The composition used to forni the inserts is preferably swept over the appropriate stencil, and the portion of the composition passing through the stencil openings forms deposits having a depth equal to the space between the backing and the stencil. The deposited granular material forming the. insets is softened by heat and compacted by pressure and firmly united to both the backing and previous deposits, which is again softened by the second heating, but is not again directly subjected to ressure. The templates or stencils containing passages for the deposit of material to form tesserae having surfaces below the general surface level of the finished product are preferably positioned closer tothe backing than are the stencils or templates containing passages for the deposit of material to form tesser which are to forni the higher portions of the surface of the completed product, and each set of stencils may be elevated by suitable means during the movement of the backing.

The pressures applied to the initial and secondary deposits are preferably such as to secure a substantially uiiform density in both groups of tesserae, and the heat softened initial and secondary deposits are firmly united to one another by the intei'mingliiig of granules along their abutting edges and the partial overlying of the initial deposit by the secondary deposit.

The backing with its compacted covering isy then finished by curing and seasoning, preferably after being subjected to the action of a suitable finishing press conforming to the surface of the product.

Y The preferred practice of my invention and the product resulting therefrom are diagram Vmatically illustrated in the accompanying drawinfy in which Fior. l is a fragmentar .D7 C D plan view illustrating a backing and a teniplate for depositing thereon an initial gridlike set of tesserae, the template being broken away to show the backing and the material deposited in granular condition; Fig. 2 is a transverse sectional View on the line 2-2 of Fig. l; Fig. 3 is a transverse sectional view illustrating the compacting of the initial deposit by a press; 4 is a fragmentary plan view of a backing on which a reticulated deposit has been compacted and a teniplate for depositing insets between the initial deposits, a portion of the template being broken away to show the patterned backing with the insets deposited thereon in granular condition; Fig. 5 is a transverse sectional view on the line 5-5 of Fig. 4; and Fig. 6 is a transverse sectional view of a fabric and press for compactiiig the insets.

As graphically illustrated in the drawing, the backing 1, preferably consisting of bur-y lap, impregnated felt or the like, is moved step by step beneath one or more templates or stencils 2 containing apertures 3 having the contour of tesserae comprised in the design to be produced. As illustrated, the passages may have a gridlike outline, so that tesserae formed from uncured plastic granular linoleum composition deposited therethrough will simulate mortar joints. Any desired number of stencils may be utilized for the deposition of the tesserae to simulate mortar joints, and variously colored plastic compositions may be used with the respective templates. The material passing through the apertures 3 is deposited on the backing in the form of intersecting ribs or ridges 4 having between them the recesses or openings 5.

The further movement of the burlap carries the deposited granular material beneath the head 6 of a. conventional form of steam heated hydraulic press, and the material comprised in the ridges 4 is compacted thereby to approximately one-third its init al thickness, so that the granules are united into an integral fretwork or grid firmly adhering to the backing.

Further step by step movement of the backing brings the recesses between the ribs into registration with apertures 7 of one or more templates or stencils 8. The template 8 is positioned at a greater distance from the backing than the stencil 2, and the apertures tlierein have contours conforming to the outline of the inset tesserae to be formed in the recesses or openings 5. Granulated, uncured, plastic linoleum composition is brushed through the opening 7 and forms deposits in the openings 5 of greater depth than the original depth of the ridges 4. Further step by step movement of the backing carries it beneath the head 9 of a second steam heated press which acts upon the loose granular material 10 in the openings or recesses 5 and compacts such material to approximately onethird its initial thickness. The heat and pressure not only unite the granules of the deposits l0 with one another, but also with the softened, uncured compacted material of the ridges 4 and to the backing.

The laminated product may, if desired, be subjected to the further action of a finishing press and then cured and seasoned with the production of a covering having a homogeneous surface lamina of irregular height simulating paving plaques spaced by mortar joints, or, by suitably shaping the template apertures, the pattern deposited may be so shaped and colored as to produce flowers, birds, geometrical figures, or any other desired appearance.

While I prefer that the plastic compositions involved in my invention be composed of oxidized linseed oil, granulated cork, wood flour, gums and pigments, other binders and fillers may be used in the composition, such for instance, as ground leather, asbestos, and plastic cellulose. All such solidifiable compositions are intended to be embraced within the term linoleum composition as used in the claims, whether or not such composition actually contains any linseed oil. i

Having described my invention, I claim v l. The method of making moulded inlaid linoleum which consists in depositing on a backing unseasoned granulated plastic linoleum composition forming tesserae having spaces between them, compacting such dem posited composition, depositing between compacted tesserae aforesaid unseasoned granulated plastic linoleum composition, and compacting said last named deposited composition.

,5 2. The method of making moulded inlaid linoleum which consists in depositing on a backing a granulated plastic in the form of tesserae having spaces between them, compacting such deposits, depositing between ,E0 such compacted deposits granulated plastic material to a greater depth than the initial deposits, and compacting such secondary deposits so as to form a surface above the surface of said initial deposits.

g5 3. The method of making moulded inlaid linoleum which consists in moving a backing beneath an apertured stencil, passing plastic uncured granulated linoleum composition through said stencil apertures to form spaced 30 deposits on said backing, softening and compacting said deposits, moving said backing into registration With apertures of a stencil conforming with spaces between said compacted deposits, passing plastic uncured '1,5 granulated linoleum composition through said last named apertures to form deposits of greater depth than said first deposits, soften-` ing said first and second deposits and compacting said second deposit. 4Q 4. The method of making moulded inlaid linoleum which consists in moving a backing beneath stencils outlining different shapes in sequence, depositing linoleum composition on said backing in shapes outlined by said stencils, deposits aforesaid being made from different distances from said backing, compacting the initial deposit on said backing before the second deposit is made thereon, and compacting the second deposit without rdirect no pressure on said first deposit.

In witness whereof I have hereunto set my name this 31st day of December, 1929.

EDWARD C. DEARDEN. 

